Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

Rypina, Łukasz; Lipiński, D.; Bałasz, Błażej; Kacalak, Wojciech; Szatkiewicz, Tomasz

doi:10.3390/ma13245835

Cited by 16 publications

(11 citation statements)

References 38 publications

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“…The finite element simulation can be employed to solve implicit problems and is widely applied in the fields of structural strength, fluid analysis, and metal cutting [16,17]. Therefore, this paper applied the Abaqus software (a type of finite element analysis product, [18]) to simulate the brush grinding process. The geometrical model of the workpiece and the abrasive grain are shown in Figure 4.…”

Section: Methodsmentioning

confidence: 99%

“…The parameters of the abrasive grain model were diameter, d = 40 µm; the cone angle, β = 80°; the rake angle, γ = 50°; and the grain weight, The finite element simulation can be employed to solve implicit problems and is widely applied in the fields of structural strength, fluid analysis, and metal cutting [16,17]. Therefore, this paper applied the Abaqus software (a type of finite element analysis product, [18]) to simulate the brush grinding process. The geometrical model of the workpiece and the abrasive grain are shown in Figure 4.…”

Section: Methodsmentioning

confidence: 99%

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Numerical and Experimental Research on the Brushing Aluminium Alloy Mechanism Using an Abrasive Filament Brush

et al. 2021

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Abrasive filament brushes have been widely used in surface processes for a wide range of applications, including blending, edge-radiusing, and polishing. However, the associated brush mechanics of material removal is still not clear. In order to analyze the brush grinding of aluminium alloy, this paper constructed a kinematic model of a single filament, simulated the scratch process of a single abrasive grain, and investigated the brush force and material removal based on the finite element approach. The simulated result shows that the brush grinding can be changed from elastic–plastic deformation to chip formation when increasing the brush speed to 1000 r/min. The normal and tangential forces increase linearly and quadratically with the increase in the rotation speed (500–5000 r/min), respectively, and increase linearly with the increase in the penetration depth (0.1–1 mm), which is consistent with the experiment results. In addition, the amount of material removal initially increases with the increase in penetration depth, and then decreases. This paper provides a new approach to understanding the process of material removal and is helpful for the selection of reasonable brush parameters in the intelligent grinding control application.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Numerical and Experimental Research on the Brushing Aluminium Alloy Mechanism Using an Abrasive Filament Brush

et al. 2021

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“…In addition to turning, milling, and drilling, cutting zone research continues for a variety of other materials [38,39] and cutting technologies such as grinding [40], milling with a disc cutter [41], and Micro and Macro Machining (MMM) [42,43] by using FEM [44] and fuzzy algorithms [45].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

et al. 2022

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The paper deals with the issue of cutting zone and chip compression. The aim was to analyse the microstructure transverse section of the cutting zone on a metallographic cut, due to determined values of chip compression and plastic deformation, which affect the cutting process efficiency. The tested cutting tool material was coated with cemented carbide. The selected workpiece materials were C45 medium carbon steel of ISO grade and 62SiMnCr4 tool steel of ISO (W.Nr. 1.2101) grade. In the experiments, a DMG CTX alpha 500 turning centre was used. The cutting speed and feed were varied, and the depth of the cut was kept constant during the turning. The plastic deformation and chip compression determine the efficiency of the cutting process. The higher compression requires more work to perform the process and, therefore, it requires more energy for doing so. With the increase of the cutting speed, the deformation for C45 steel is decreased. The rapid deformation reduction was observed when the cutting speed was increased from 145 m/min to 180 m/min. Generally, deformation is decreasing with the increase of the feed. Only at a cutting speed of 145 m/min was the deformation elevation observed, when the feed was increased from 0.4 mm to 0.6 mm. During the turning of the 62SiMnCr4 tool steel we observed an error value at a cutting speed of 145 m/min and a feed of 0.4 mm was the middle cutting parameter. However, feed dependence was clear: With an increase of the feed, the plastic deformation was decreasing. This decreasing was more rapid with the increasing of the cutting speed. Besides plastic deformation, there was analysed chip compression as well. With the increasing of the cutting speed, there was a decrease of the chip compression. Due to a lack of information in the area of the chip compression and the plastic deformation in the cutting process, we decided to investigate the cutting zone for the turning of tool steels 62SiMnCr4, which was compared with the reference steel C45. The results could be applied to increase the efficiency of the process and improvement of the surface integrity.

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“…The authors of Rypin et al used a high-speed camera to analyze the course of cutting with a single abrasive grain in order to create a geometric model that was used to develop a computer model of micro-cutting with a single abrasive grain [ 26 ].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

2021

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The paper presents the possibilities of a high-speed camera in recording displacements of thin-walled workpiece during milling made of aluminum alloys, which allowed for an analysis in which it was compared to other methods of testing the deflection of such elements. The tests were carried out during peripheral milling with constant cutting parameters. Deflection of thin-walled workpiece due to cutting forces was measured using a high-speed camera and a laser displacement sensor. Additionally, the experimental results were compared with the theoretical results obtained with the use of the finite element method. The research proved the effectiveness of the use of high-speed camera in diagnostics of thin-walled workpieces during milling with an accuracy of up to 11% compared to measurements made with a displacement laser sensor.

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Analysis and Modeling of the Micro-Cutting Process of Ti-6Al-4V Titanium Alloy with Single Abrasive Grain

Cited by 16 publications

References 38 publications

Numerical and Experimental Research on the Brushing Aluminium Alloy Mechanism Using an Abrasive Filament Brush

Numerical and Experimental Research on the Brushing Aluminium Alloy Mechanism Using an Abrasive Filament Brush

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

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